Production process 
  CERACASA has one of the most modern installations in the sector dedicated to the production, management and logistics for ceramic products like EMOTILE by CERASCASA©. The two industrial levels of more than 130,000m2 are divided into different sections which complete the process of CREATION, DESIGN, PRODUCTION, WAREHOUSING and SHIPPING.
Our Products

CERACASA’s products offer durability, resistance (to detergents, fire, knocks, impact, acids…) hygiene (odour free, easy cleaning, dust free, non-porous) and great beauty in all styles (polished, satin, matte, non-slip…)		 Advanced Technology

The production process of CERACASA products is highly advanced, applying the most up to date technology in the market: laser guide, integrated automation, digital injection decoration, classification by artificial eye and specialised control programmes.		 Quality control

Our internal laboratories carry out checks of the raw materials, a comprehensive, traceable quality follow up and checks of the finished products in order to ensure high quality products. In addition, external laboratories periodically test our products and guarantee them with technical certificates.
Laboratory

The raw materials are mixed following a tried and tested formula. The main materials are: feldspar 50%, clay 30%, Kaolin 10%, sand 9% and 1% additives (Deflocculants). The pigments to colour the paste (piece) vary according to the model and are added after.		 Alsing Mills

This mix is prepared in Alsing Mills, which through friction and the controlled weight of aluminium balls obtain a dense liquid called Barbotine. This Barbotine contains the formula which will give us the type of product (white or red-bodied tiles, stoneware or porcelain) and is placed in storage before being coloured.		 Spray drying

Once the Barbotine has been coloured, the humidity is removed through a process known as spray drying. As the name suggests, the material is dried by a spray of hot air. This dust, with a humidity of between 5-6% is stored in silos before being pressed.
Silos

Once the spray dried mix is stored in a silo, it can be mixed to obtain one type or other of tile – white or red, stoneware or porcelain. For this process CERACASA uses the latest technology available on the market.		 Presses

When we have the desired type of dried mix it is passed to the pressing section where it is compacted under extreme pressure in order to leave as few gaps between the particles as possible (which is why the product has such strength and zero-porosity, above all in porcelain). This section has the best pressing machinery, from small sizes (33x33 cms) to large (49.1x98.2 cms) with the possibility to adapt to even larger sizes.
 
Driers

At this point the piece has a humidity level (between 4-5%) which needs to be eliminated in a drier. At a constant temperature, the humidity is lowered to practically zero before the piece is decorated or glazed.		 Decoration line

The decoration lines are over 200 metres long. First of all a thin coating of glaze is applied to a warmed, stationary tile. After this, it can be decorated by one of three methods (screen printing, photogravure and/or injection).		 Decorative methods

Each one of these three methods gives different characteristics; high, medium or low shades. Decoration of 100% of the surface, with relief or with photographs. EMOTILE ® injection system.
     
Kilns

The decorated pieces, still un-fired, pass to the kiln section. In this area, CERACASA tiles are finished off to give the final qualities, among which are: high resistance and low porosity in the porcelain products.		 Kiln temperatures

The raw piece enters in one end of the115 metre long kiln and via a roller conveyor and is moved to the interior whilst being exposed to different temperatures at different points (the firing curve) which lasts between 45 and 60 minutes (firing cycle). During the course of this cycle the piece reaches 1200ªc. At these temperatures the porcelain reaches the afore mentioned properties.		 Finishes

Once the Porcelain is fired we obtain the glazed finish applied in raw: matte, satin or non-slip. CERACASA offers an exclusive HIGH SHINE finish to add an even more attractive touch to the spaces covered. The pieces glazed with special grains or grits are polished in a specialised continuous, moving abrasive machine of over 50 metres in length, which offers an unbeatable shine.
Polishing machines

These polishing machines are also equipped to rectify and bevel edges for greater ease in the handling and laying of the tiles. They are sorted automatically and are arranged for storage.
 
And with that last phase, we finish the production chain at CERACASA

A finished product apt for use in any situation or architectural project.